Build 1978 US Market FJ40 Factory Restoration

[dmaddox]

Coming together, I should have finished today, then onto steering.

Blue pads....not sure why blue.

Note the stack of anti-mosquito warfare. I think they just smoke it like a fat Cuban and bite me anyway.

Restored exhaust manifold snuck into the picture, too!

 

[mrboatman]

Thats looking real nice.

 

[dmaddox]

Finished driver. Will wrap up passenger and begin steering. One bite at a time.

 

[dmaddox]

I had a question on the wheels. As delivered back in the late 70's were both sides of the wheels gray, or just the exposed areas? Curious, thank you.

 

[SteveH]

Looks great! I thought OEM (front) brake pads for the FJ40/60 were discontinued - did you get those at a dealer, or online? Who has them?

 

[dmaddox]

I purchased the pads new from Toyota - looks like they still make them. I used THIS link.

 

[Goldbug]

Great work, looks terrific. I’ve found really good pricing for OEM from a place near me, Ernie Boch Toyota. Website is tough, you have to know the part number, but prices are way below most others.

 

[dmaddox]

I’m now working on the front brake lines. I ordered 96940-32605 for the hose that attaches the front axle to the right side of the frame.

Is this supposed to seat in here properly or do I have the wrong hose or union? Not sure if this is supposed to stick out? I have it all the way in:

 

[Curtice]

I had the exact same question. I called SOR who I bought my brake lines from and they walked me through how it works. I believe you have it correct...you can see mine on post #100 on my build thread:

Build - 78 body off restore (cruiser #2)

The plating is awesome. Sorry to ask, but I also have some plating I need to do, what did you request and what kind of shop would I look for? Gold zinc? Is it expensive? thank you!

forum.ih8mud.com

As I noted on my post, the rear one is not the same and will not poke out like that. Make sure you have a copper washer on the rear one to seal it.

 

[dmaddox]

Cool - thank you Curtice. Much appreciated and I just read through yours as well. Thank you!

 

[dmaddox]

I have enjoyed this little double flare tool while building all of my brake lines. Yes it is one size, but the flare is perfect every time. No clamps, wing nuts or threaded marring on the line. Simple and agile. 17 and 10mm spanners and you’re good to go.

 

[ToyotaMatt]

By now Dallas ,

Your sourced 1978 model year specific requested and white tag PLANT A11 Stamped fully restored rear jump seat lap belt kits should be shining bright chrome on your dining room table this evening by now ?

These were one of the top 10 hardest Unicorn Hunter Request list items I have ever had to make happen

Again your big picture project and your vision of a period correct build theme continues to fascinate me and sets a new Bar. Each time i check in to see what’s up here .....

 

[dmaddox]

Thank you @ToyotaMatt, a great find. They will be going into a deserving truck!

I just finished restoring the intake and exhaust manifolds. Which I used @ToyotaMatts EGR repair kit and downpipe repair kit. I am in the process of restoring the EGR itself, and should have that installed this weekend along with the downpipe.

After that, fuel lines and electrical (rear harness) and I will roll/set aside the chassis and get back to the chopper, tub and try to wrap that up so that I can get some mustard sprayed sooner than later.

I did finish all of the chassis brake lines.
Any other ideas on what I need to wrap up on the chassis before plopping the tub on it?

 

[tls3601]

I had a question on the wheels. As delivered back in the late 70's were both sides of the wheels gray, or just the exposed areas? Curious, thank you.

I also have a ‘78. Only the outside of the rims were gray, inside was black

 

[tls3601]

Stunning build you have there sir Following

 

[dmaddox]

Spent the day wrestling with the EGR restoration, fitting, etc..

Luckily, @ToyotaMatt provides an early and late EGR kit, so the hardware is fresh and made the job much easier.

I had two EGR setups, one was pretty chewed up and used, but was able to take both of them completely apart and restore a nice setup for the project.

I used high temp silver on the aluminum and high temp black on the cast iron back piece.

Fitting the EGR cooler:

After wrestling with it more, I had to remove and run an M10x1.25 (i think it was) tap into the block where the cooler mounted. That did the trick, as the engine paint, etc.. was quit built up.

I was lucky enough to have the rear exhaust shield. The front is in the mail. I should have it installed this week. It is important because it has the snorkel for the heat riser.

Here, I finished the support bracket and u-bolt for the accordion pipe:

Downpipe installed:

The downpipe has a support bracket that secures to the motor mount (rear left) - I didn't know this, until digging through some parts and realized THAT was what the bracket was for!

 

[dmaddox]

More engine components going on, I am about to a stopping point and moving onto the tub/body work. Here, I thought I'd "show off" a little. Let me know if you guys see anything incorrect. I am lego'ing this thing together best I can, but am sure to screw something up.

Thanks!

 

[rkymtnflyfisher]

That is some amazing work!

 

[TheHardWay]

Wow. I've read a lot of build threads here - never get tired of it. Good job!

 

[TEQ]

Wow. I've read a lot of build threads here - never get tired of it. Good job!

I came here to say this.